GUJARAT TECHNOLOGICAL UNIVERSITY (GTU)

Competency-focused Outcome-based Green Curriculum-2021 (COGC-2021)

Semester- VI
Course Title: Instrumentation and Process Control
(Course Code: 4360504)

Diploma programme in which this course is offered Semester in which offered

Chemical Engineering 6th Semester

1. RATIONALE

The course aims to provide students with a comprehensive understanding of process control and
instrumentation. It covers the foundational principles of process control, including application of
Laplace transform approach for single loop systems, analysis of dynamic responses in open and
closed loop systems, Furthermore, the course delves into the practical application of various
controllers, such as P, PI, PD and PID. In addition to control theory, the course emphasizes
instrumentation for process control and offers hands-on experience. It covers the operational
principles of different measuring devices for variables like temperature, level, pressure, and flow.
The course also introduces students to the concept of PLC and DCS.

2. COMPETENCY

The course should be taught, and curriculum should be implemented with the aim to develop require
skills so that students are able to acquire following competency: Student will be able to apply the
concept of process control and measure various process parameters in chemical industry.

3. COURSE OUTCOMES (COs)

1) Apply the basic concept of process control in the chemical industry.
2) Apply basic concepts of various controllers in process control.
3) Select appropriate instruments to measure various process parameters in chemical plants.
4) Measure various process parameters in the chemical industry using relevant devices.

4. TEACHING AND EXAMINATION SCHEME

Teaching Scheme Total Credits Examination Scheme

(In Hours) [L+T+(P/2)]
Theory Marks Practical Marks Total
Marks
L T P C CA ESE CA ESE

2 0 2 3 30* 70 25 25 150

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(*): Out of 30 marks under the theory CA, 10 marks are for assessment of the micro-project to facilitate the
integration of COs, and the remaining 20 marks are the average of 2 tests to be taken during the semester
for assessing the attainment of the cognitive domain UOs required for the attainment of the COs.
Legends: L-Lecture; T-Tutorial/Teacher Guided Theory Practice; P-Practical; C-Credit, CA -Continuous
Assessment; ESE-End Semester Examination.

5.SUGGESTED PRACTICAL EXERCISES

The following practical outcomes (PrOs) are the subcomponents of the Cos.
Sr. Unit No. Approx.
No. Practical Outcomes (PrOs) Hrs.
required

1 Dynamics Of First Order System (Step and Impulse Response Of 1 02

thermometer)

2 Dynamics Of First Order System (Step Response of Single Tank Liquid Level 1 02
System)

3 Dynamics Of Two First Order Systems Connected in Series (Step Response 1 02

Non-Interacting System)

4 Dynamics Of Two First Order Systems Connected in Series (Impulse Response 1 02

Non- Interacting System)

5 Dynamics Of Two First Order Systems Connected in Series (Step Response of 1 02

Interacting System)

6 Dynamics Of Second Order System (Step Response Of U-Tube Manometer) 1 02

7 Measure level using direct method 4 02

8 Measure temperature of fluid using bimetallic thermometer 4 02

9 Measure temperature of fluid using thermocouple 4 02

10 Prepare a chart of components of DCS system 2 02

11 Measure specific gravity by Hydrometer 4 02

12 Level controller trainer 2 02

13 Flow controller trainer 2 02

Total 26Hrs.

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NOTE: More Practical Exercises can be designed and offered by the respective course teacher to develop
the industry relevant skills/outcomes to match the Cos. The above table is only a suggestive list.

The following are some sample (suggested) ‘Process’ and ‘Product’ related skills (more may be
added/deleted depending on the course) that occur in the above listed Practical Exercises of this course
required which are embedded in the COs and ultimately the competency.

Sr. No Sample Performance Indicators for the PrOs Weightage in %

1 Handling of apparatus for precise measurements. 10
2 Record observations correctly 20
3 Practice and adapt good and safe measuring techniques 10
4 Calculations, Interpretation of results and their 20
conclusion.
5 Prepare a practical report in prescribed format. 10
6 Solve assignment questions. 20
7 Viva-voce 10
Total 100

6.MAJOR EQUIPMENTS/ INSTRUMENTS REQUIRED

Sr. No. PrO. No.
Equipment Name with Broad Specifications

1 Interactive & Non-Interacting System Apparatus: 3, 4, 5

Process Tank: Material Stainless Steel, Circular, with level scale (3 Nos.) Capacity:
2.5 to 3.5 liters. Supply Tank: Material Stainless steel, Capacity 20 liters. Overhead
tank: Material Stainless steel, Capacity 5 liters. Water Circulation: FHP Pump,
Tullu/Standard make. Piping: SS/PVC, size Flow Measurement: Rotameter.
Instruction Manual: An ENGLISH instruction manual will be provided along with the
Apparatus. The whole unit is assembled rigidly on a base plate. Most of the parts
are powder coated and the rest are painted with auto paints. SERVICES REQUIRED
Water supply Drain Electrical supply: 1 Phase, 220V AC, 0.5 kW. Table for set-up
support. Processes when connected in interacting and non-interacting mode. It is
a combined unit to study 1) Single capacity process. 2) Non interacting process
different mode can be compared with mathematically predicted response. Setup
consists of supply tank, pump for water circulation, Rota meter for flow
measurement, process tanks with scales, which can be connected to interacting
and non-interacting mode. The components are assembled on frame to form
tabletop set-up. line-height:

7. AFFECTIVE DOMAIN OUTCOMES

The following sample Affective Domain Outcomes (ADOs) are embedded in many of the above-
mentioned COs and PrOs. More could be added to fulfill the development of this competency.
a) Work as a leader/a team member.
b) Follow ethical practices

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 c) Observe safety measures
d) Good house keeping
e) Time management
f) Practice environmentally friendly methods and processes.
The ADOs are best developed through laboratory/field-based exercises. Moreover, the level of
achievement of the ADOs according to Krathwohl’s ‘Affective Domain Taxonomy’ should gradually
increase as planned below:
i. ‘Valuing Level’ in 1st year
ii. ‘Organization Level’ in 2nd year.
iii. ‘Characterization Level’ in 3rd year.

8.UNDERPINNING THEORY
The major underpinning theory is given below based on the higher level UOs of Revised Bloom’s
taxonomy that are formulated for development of the Cos and competency. If required, more such
higher-level UOs could be included by the course teacher to focus on the attainment of COs and
competency.

Unit Unit Outcomes (UOs) Topics and Sub-topics

Unit – I 1.Explain Need for control and 1.1 Introduction of Process Control: Need for
automation in process control. control and automation.
1.2 Steady state and dynamic system
Introduction of 2.Explain Steady state and dynamic
1.3 Servo and regulatory control, Open and
Process Control system.
3.Explain servo and regulatory system. close loop block diagrams
&
1.4 The Control Systems: Block diagram,
Control Systems 4.Development of Block diagram of
process controller. Standard block diagram symbols, Negative and
5.Apply basics of Laplace transform. positive feedback, Development of block
6.Explain Negative and positive feedback. diagrams, Process measuring element,
Controller, Final control element.
7. Explain First order system and second
order system with examples of different 1.5 Basic concept of Laplace transform.
systems. 1.6 First order system: Mercury thermometer,
interacting and non-interacting liquid level
system.
1.7 Second order system: U-Tube manometer.

Unit– II 1. Justify need for controllers. 2.1 Controllers and Final Control Elements
2. Explain Pneumatic controller. 2.1.1 Pneumatic controller mechanism of
Controllers and mechanism of PI, PD, PID control. Proportional control, Proportional integral (PI)
Final Control control, Proportional derivative (PD) control,
3. Explain response of various modes
Elements Proportional integral derivative (PID) control.
of control. 2.1.2 Response of a typical control system
4. Explain schematic of control loops. showing the effects of various modes of control
5. Explain PLC, DCS system. (no control, P, PI, PID)
2.1.3 Control loops: Temperature control,
Pressure control, Flow control, Level control

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 Unit Unit Outcomes (UOs) Topics and Sub-topics

2.1.4 PLC, DCS

Unit– III 1. Justify need for instrumentation in 3.1 Introduction of Process Measurement:
chemical plant. Importance of instrumentation in chemical
Introduction to 2. Classify instruments in chemical plant
Process plant. 3.2 Classification of instruments
Measurement 3.3 Basic elements of instruments
3. Describe Basic elements of
3.4 Static and dynamic characteristics
instruments.
3.5 Selection criteria for various measuring
4. Compare Static and Dynamic
devices in chemical industry for: Temperature,
Characteristics of instruments. Pressure, Level and Flow
5. Select appropriate instrument for
measurement based on instrument
range.

Unit– IV
Measuring 1. Compare different types of 4.1 Temperature Measurement:
Devices temperature measurement 4.1.1 Principle, Construction & Working of:
4.1.1.1 Bi-metallic thermometer
devices.
4.1.1.2 Resistance thermometer
2. Explain Principle, Construction & 4.1.1.3 Industrial thermocouple: their
Working of: Bi-metallic, Resistance principle, construction, working range, lead
thermometers, Industrial wires.
thermocouple, Radiation and 4.1.1.4 Radiation and optical Pyrometers
optical Pyrometers. 4.2 Pressure Measurement:
3. Describe principal construction, 4.2.1 Pressure gauges: Principle, construction
and working:
and working of Bourdon tube
4.2.2.1 Bourdon tube gauge
gauge, Dead weight Gauge. 4.2.2.2 Dead weight gauge
4. Describe principle, construction, 4.3 Flow Measurement: Principle,
and working of Target meter. construction and working of Target meter
5. Classify and explain level 4.4 Measurement of head & level: Principle,
measuring devices. construction and working:
4.4.1 Direct level measuring devices
4.4.1.1 Probe and tape
4.4.1.2 Sight glass
4.4.2 Indirect level measuring devices:
4.4.2.1 Air trap box method
4.4.2.2 Diaphragm box method

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 9. SUGGESTED SPECIFICATION TABLE FOR QUESTION PAPER DESIGN

Unit Unit Title Teaching Distribution of Theory Marks

No. Hours
R U A Total
Level Level Level Marks

I Introduction of Process Control & 11 7 7 3 17

Control Systems

II Controllers and Final Control Elements 07 8 8 3 19

III Introduction of Process Measurement 03 4 3 1 8

IV Measuring Devices 07 10 10 6 26

Total 28 29 28 13 70

Legends: R=Remember, U=Understand, A=Apply and above (Revised Bloom’s taxonomy)

Note: This specification table provides general guidelines to assist students for their learning and
to teachers to teach and question paper designers/setters to formulate test items/questions to
assess the attainment of the UOs. The actual distribution of marks at different taxonomy levels
(of R, U and A) in the question paper may slightly vary from the above table.

10.SUGGESTED STUDENT ACTIVITIES:

Other than the classroom and laboratory learning, following are the suggested student-related co-
curricular activities which can be undertaken to accelerate the attainment of the various outcomes in
this course: Students should perform following activities in group and prepare reports of about 5 pages
for each activity. They should also collect/record physical evidence for their (student’s) portfolio which
may be useful for their placement interviews:

Following is the list of proposed student activities like:

1. Assignments
2. Technical Quiz/MCQ Test
3. Presentation on some course topic
4. I-net based assignments
5. Undertake micro-Project in team/individually

11.SUGGESTED SPECIAL INSTRUCTIONAL STRATEGIES (if any)

These are sample strategies, which the teacher can use to accelerate the attainment of the various
outcomes in this course:
a) Massive open online courses (MOOCs) may be used to teach various topics/subtopics.

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 b) Guide student(s) in undertaking micro-projects/activities.
c) Different types of teaching methods i.e., video demonstration, activity-based learning, case study,
m-learning need to be employed by teachers to develop the outcomes.
d) Some of the topics/sub-topics which are relatively simpler or descriptive are to be given to the
students for self-learning but to be assessed using different assessment methods.
e) Teachers need to ensure to create opportunities and provisions for co-curricular activities.
f) Guide students to address issues on environment and sustainability with reference to using the
knowledge of this course.
g) OERs and Vlab may be used to teach for the teaching of different concepts.

12.SUGGESTED MICRO-PROJECTS

Only one micro-project is planned to be undertaken by a student that needs to be assigned to him/her at
the beginning of the semester. In the first four semesters, the micro-project is group-based (group of 3 to
5). However, in the fifth and sixth semesters, the number of students in the group should not exceed three.
The micro-project could be industry application-based, internet-based, workshop-based, laboratory-based,
or field-based. Each micro-project should encompass two or more COs which are the integration of PrOs,
UOs, and ADOs. Each student will have to maintain a dated work diary consisting of individual contributions
to the project work and give a seminar presentation of it before submission. The duration of the
microproject should be about 14-16 (fourteen to sixteen) student engagement hours during the course.
The student sought to submit micro-project by the end of the semester (so that they develop industry-
oriented COs).
A suggested list of micro-projects is given here. This should relate highly to the competency of the course
and the COs. Similar micro-projects could be added by the concerned course teacher.

1) Prepare chart on working of PLC and DCS system.

2) Predict accuracy and precision of a standard measurement equipment
3) Prepare charts on First order dynamics for mixing process, temperature measurement, liquid level
measurement etc.
4) Prepare a chart on liquid level equipment.
5) Prepare a PowerPoint presentation on a topic “P, PI, PD, PID controllers.”
6) Interpret PID diagram of a chemical industrial process.

13. SUGGESTED LEARNING RESOURCES

Sr. Author Publication with place,

Title of Book
No. year, and ISBN

1 Process Systems Analysis and Donald Coughanowr, 3rdedition, McGraw-Hill (2009)

Control Steven E. LeBlanc

2 Fundamentals of Industrial William C. Dunn Mc-Graw-Hill (2005)

Instrumentation and Process Control

3 Industrial Instrumentation and Control S.K. Singh 3rd edition, McGraw-Hill (2008)

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 Sr. Author Publication with place,
Title of Book
No. year, and ISBN

4 Process Control and Instrumentation R. P. Vyas Denett & Co. (2015)

5 Industrial Instrumentation Donald P. Eckman John Wiley & Sons Inc, New York
(2019)

6 Practical Process Control for Engineers Wolfgang Altmann Elsevier Science (2005)
and Technicians

7 Chemical Process Control: An Introduction George Pearson Education India (2015)

to Theory and Practice Stephanopoulos

8 Instrument Engineers' Handbook, Volume Bela G. Liptak (Editor) 5th edition, CRC Press (2016)
1: Process Measurement and Analysis

14.SOFTWARE/LEARNING WEBSITES

Students can refer to video lectures available on websites including NPTEL.

• https://nptel.ac.in/courses/103103037
• https://www.tec-science.com/thermodynamics/temperature/how-does-a-bimetallic-strip-
thermometer-work/ (Bimetallic thermometer animation)
• http://users.telenet.be/instrumentatie/temperature/temperature-scales.html (Temperature
scales)
• https://en.wikipedia.org/wiki/Thermometer (Thermometer)
• https://instrumentationtools.com/bimetallic-thermometer/ (Bimetallic thermometer)

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15.PO-COMPETENCY-CO MAPPING

Instrumentation and Process Control (4360504)

Semester-VI
Pos
PO 5
PO 3 PO 4 Engineering PO 6
Competency PO 1 PO 2 Design/ Project PO 7
Engineering Tools, practices for
& Course Basic & Discipline Problem Life- long
development Experimentation & society, Manageme
Outcomes specific knowledge Analysis learning
of solutions Testing sustainability & nt
Environment

Competency Student will be able to apply the concept of process control and measure various
process parameters in chemical industry.

4360504.1 3 2 - 3 2 1 2

4360504.2 2 3 2 1 2 2 2

4360504.3 2 3 2 2 2 2 2

4360504.4 3 2 2 3 2 2 3

Legend: ‘3’ for high, ‘2’ for medium, ‘1’ for low and ‘-’ for no correlation of each CO with PO.

16.COURSE CURRICULUM DEVELOPMENT COMMITTEE

GTU Resource Persons

Name and
Sr. No. Institute Contact No. Email
Designation

Mr. M.P Deshpande

(Lecturer in
1 G.P Valsad - [email protected]
chemical
Engineering)

Mr. J.D Rathod

(Lecturer in
2 G.P Valsad - [email protected]
chemical
Engineering)

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